Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide

Bumpers

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REMOVAL & INSTALLATION



The bumpers, front or rear, are actually assemblies. The outer surface is the cover or fascia, behind which may be found absorbent materials (foam block or honeycomb lattice) and the reinforcing steel bar. The components cannot be removed separately; the entire assembly must be removed from the car and then broken down into individual pieces.


CAUTION
The bumper assemblies are heavy! Always support the bumper from below in at least two places before removing the last bolts. Never lie under the bumper while removing it.

The bumper covers are generally made of urethane. If this heavy, flexible plastic receives minor damage, generally under 1 in. (25mm), it can be repaired by a reputable body shop using established industry methods. Like any body repair, the bumper will require painting and should be removed from the car. In the event of more extensive damage, the cover can be replaced individually after the bumper is removed. This will save the cost of a complete bumper assembly.

Montero

See Figures 1 and 2

Straightforward and simple, the Montero bumpers are removed from either end by removing the 4 bolts holding the unit to the mounts. The rear bumper has 4 additional bolts-2 at each side-at the leading edge of the bumper corner trim. Although the bumpers are simple to remove, they are still heavy; be careful!

  1. On the front bumper, remove the lower skid plate from the vehicle. The skid plate is held in place by four or more retaining bolts. Remove the five bumper garnish retaining nuts from the underside of the top of the bumper, then remove the bumper garnish.
  2.  

  1. Some vehicles are equipped with a bumper mounted outside temperature sensor. Remove this before complete removal of the bumper.
  2.  
  3. Loosen and remove the bumper retaining bolts (four total for the front, ten or eight total for the rear). Have an assistant or a floor jack support the bumper while removing the mounting bolts.
  4.  


CAUTION
Be careful when removing the mounting bolts from the bumper, the bumper assemblies are heavy and can cause personal harm.

To install:
  1. Using a floor jack or an assistant, position the bumper in place. Install the mounting bolts and tighten front bumper bolts to 60 ft. lbs. (81 Nm), rear bumper bolts to 33 ft. lbs. (44 Nm).
  2.  
  3. Install the outside temperature sensor, if the vehicle is equipped with one.
  4.  
  5. Install the bumper garnish and the skid plate on the front bumper. Tighten the skid plate front bolts to 17 ft. lbs. (24 Nm) and the rear bolts to 8 ft. lbs. (12 Nm).
  6.  

Pick-Up
FRONT

See Figures 3 and 4

  1. Remove the 5 bolts holding the front skirt panel to the bumper.
  2.  
  3. Disconnect the wiring to the front turn signal lights. The lights may stay in the bumper if you wish.
  4.  

  1. Disconnect the front bumper from the side stays on each side.
  2.  
  3. Remove the bolts attaching the front bumper support to the frame and remove the front bumper.
  4.  

To install:
  1. When reinstalling, place the bumper on the truck and tighten the retaining bolts finger-tight. Align the holes and install the side bolts to the side stays.
  2.  
  3. Check the bumper for correct alignment; it should not sag or hang on an angle. Adjust its position as needed and tighten the bolts.
  4.  
  5. Connect the wiring for the turn signals.
  6.  
  7. Install the front skirt panel.
  8.  



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Fig. Fig. 1: Front bumper removal and installation components-Monteros



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Fig. Fig. 2: Rear bumper removal and installation components-Monteros



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Fig. Fig. 3: Front bumper removal and installation components-1983-92 Pick-ups



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Fig. Fig. 4: Front bumper removal and installation components-1993-95 Pick-ups

REAR

Not all Pick-ups are delivered with rear bumpers. Those that do have bumpers at the rear may have either the optional Mitsubishi bumper or one of a number of aftermarket products. In general, the rear bumper simply bolts to the frame, but the style and manufacture of the bumper may affect its installation.

Removal of these bumpers is generally straightforward, but be warned that some bumpers, notably the plate steel ones, are extremely heavy! Use a floor jack to help support the unit and have an assistant handy throughout the removal or installation. If the bumper contains any lighting or electrical equipment, remember to disconnect or remove it before separating the bumper from the truck.

 
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